ESAB 251 FABRICATOR® Mig Welding Machine User manual

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FABRICATOR

®

MIG WELDING MACHINE

251

Service Manual

Revision No: AK Issue Date: April 17, 2012 Manual No.: 0-4786B

Operating Features:

WE APPRECIATE YOUR BUSINESS!

Congratulations on your new Thermal Arc product. We are proud

to have you as our customer and will strive to provide you with the

best service and reliability in the industry. This product is backed

by our extensive warranty and world-wide service network. To

locate your nearest distributor or service agency call

1-800-462-2782, or visit us on the web at www.Thermalarc.com.

This Operating Manual has been designed to instruct you on the

correct use and operation of your Thermal Arc product. Your

satisfaction with this product and its safe operation is our ultimate

concern. Therefore please take the time to read the entire manual,

especially the Safety Precautions. They will help you to avoid

potential hazards that may exist when working with this product.

YOU ARE IN GOOD COMPANY!

The Brand of Choice for Contractors and Fabricators Worldwide.

Thermal Arc is a Global Brand of Arc Welding Products for

Thermadyne Industries Inc. We manufacture and supply to major

welding industry sectors worldwide including; Manufacturing,

Construction, Mining, Automotive, Aerospace, Engineering, Rural

and DIY/Hobbyist.

We distinguish ourselves from our competition through market-

leading, dependable products that have stood the test of time.

We pride ourselves on technical innovation, competitive prices,

excellent delivery, superior customer service and technical

support, together with excellence in sales and marketing expertise.

Above all, we are committed to develop technologically advanced

products to achieve a safer working environment within the

welding industry.

WARNINGS

Read and understand this entire Manual and your employer’s safety practices before installing,

operating, or servicing the equipment.

While the information contained in this Manual represents the Manufacturer's best

judgement, the Manufacturer assumes no liability for its use.

Fabricator 251 MIG Welding Machine

Service Manual Number 0-4786B for:

Package System Part Number 100048D-002

Power Source Part Number 707237

Published by:

Thermadyne Inc.

82 Benning Street

West Lebanon, New Hampshire, USA 03784

(603) 298-5711

www.thermalarc.com

Thermadyne Industries Inc.

Reproduction of this work, in whole or in part, without written permission of the pub-

lisher is prohibited.

The publisher does not assume and hereby disclaims any liability to any party for any

loss or damage caused by any error or omission in this Manual, whether such error

results from negligence, accident, or any other cause.

Publication Date: June 15, 2006

Revision AK Date: April 17, 2012

Record the following information for Warranty purposes:

Where Purchased: ____________________________________

Purchase Date: ____________________________________

Equipment Serial #: ____________________________________

i

TABLE OF CONTENTS

SECTION 1:SAFETY INSTRUCTIONS AND WARNINGS ................................................ 1-1

1.01 Arc Welding Hazards ............................................................................... 1-1

1.02 Principal Safety Standards ...................................................................... 1-4

1.03 Precautions De Securite En Soudage A L’arc ........................................... 1-5

1.04 Dangers relatifs au soudage à l’arc .......................................................... 1-5

1.05 Principales Normes De Securite .............................................................. 1-8

SECTION 2:INTRODUCTION .............................................................................. 2-1

2.01 How To Use This Manual ......................................................................... 2-1

2.02 Equipment Identiﬁcation .......................................................................... 2-1

2.03 Symbol Chart .......................................................................................... 2-2

2.04 General Information ................................................................................ 2-3

2.05 Safety ...................................................................................................... 2-3

2.06 Protective Filter Lenses ........................................................................... 2-3

2.07 User Responsibility ................................................................................. 2-3

2.08 Duty Cycle ............................................................................................... 2-4

2.09 Speciﬁcations for Fabricator 251 ............................................................. 2-4

2.10 Included Items for Fabricator 251 ........................................................... 2-6

2.11 Optional Accessories ............................................................................... 2-6

SECTION 3:INSTALLATION ................................................................................ 3-1

3.01 Environment ............................................................................................ 3-1

3.02 Location .................................................................................................. 3-1

3.03 Ventilation ............................................................................................... 3-1

3.04 Primary Power Requirements ................................................................. 3-2

3.05 Alternative Primary Input......................................................................... 3-2

3.06 Quick Setup ............................................................................................. 3-4

3.07 Installation of Shielding Gas (GMAW) Process........................................ 3-4

3.08 Attaching the Gun and Cable Assembly to the Power Source .................. 3-7

3.09 Input And Output Wire Guide Installation ................................................ 3-9

3.10 Selection and Installation of Feedrolls ..................................................... 3-9

3.11 Installing Wire Spool ............................................................................. 3-10

3.12 Inserting Wire into the Feedhead .......................................................... 3-11

3.13 Wirefeeder Feed Roll Pressure Adjustment ........................................... 3-12

3.14 Wire Spool Hub Brake ........................................................................... 3-12

3.15 Spool Gun Attachment .......................................................................... 3-13

3.16 Polarity Changeover .............................................................................. 3-14

TABLE OF CONTENTS (continued)TABLE OF CONTENTS

SECTION 4:OPERATION .................................................................................... 4-1

4.01 Power Supply Controls, Indicators and Features ..................................... 4-1

4.02 Weld Mode Selector ................................................................................ 4-6

4.03 TWECO Weldskill 300 AMP Weld Gun ..................................................... 4-8

4.04 Installing A New Wire Conduit ................................................................. 4-9

4.05 MIG Gun Maintenance ........................................................................... 4-10

4.06 Basic Welding Technique ....................................................................... 4-10

4.07 Stitch Welding Operation ....................................................................... 4-12

4.08 Spot Welding Operation ........................................................................ 4-13

4.09 Gas Selection for Gas Metal Arc Welding .............................................. 4-14

4.10 Welding Setting Selection Guide ........................................................... 4-16

SECTION 5:MAINTENANCE & TROUBLESHOOTING ................................................... 5-1

5.01 Routine Maintenance & Inspection .......................................................... 5-1

SECTION 6:TROUBLESHOOTING ......................................................................... 6-1

6.01 Basic Troubleshooting ............................................................................. 6-1

6.02 Solving Problems Beyond the Welding Terminals .................................. 6-2

6.03 Welding Problems ................................................................................... 6-4

6.04 Power Supply Problems .......................................................................... 6-6

SECTION 7:ADVANCED TROUBLESHOOTING ........................................................... 7-1

7.01 Preliminary Checks.................................................................................. 7-1

7.02 Initial Setup Conditions ........................................................................... 7-2

7.03 Primary Power Test ................................................................................. 7-2

7.04 Logic and Control Tests ........................................................................... 7-3

7.05 Spool Gun Control (J1) Test ................................................................... 7-4

7.06 Output Voltage Test ................................................................................. 7-5

7.07 Wire Feed & Weld Test ............................................................................ 7-6

7.08 Primary Power Problems ........................................................................ 7-6

7.09 Logic and Control Problems .................................................................... 7-7

7.10 Spool Gun Control (J1) Problem ............................................................. 7-8

7.11 Output Voltage Problem .......................................................................... 7-8

7.12 Wire Feed and Weld Problems ................................................................ 7-9

7.13 Terminal Block Voltage Test ..................................................................... 7-9

7.14 SW3 Coarse and SW4 Fine Rotary Switch Test ..................................... 7-10

7.15 MIG Timer PCB (PCB2) Test .................................................................. 7-12

7.16 Rectiﬁer Assembly Test ....................................................................... 7-13

7.17 Main Transformer Test........................................................................... 7-14

TABLE OF CONTENTS

SECTION 8:CIRCUIT OPERATION ......................................................................... 8-1

8.01 Circuit Operation Of The Control PCB 7977964 ....................................... 8-1

8.02 Circuit Operation Of The MIG Timer PCB 7977965 .................................. 8-2

8.03 Circuit Operation Of The Digital Volt/Amp PCB 704883 ........................... 8-2

8.04 Circuit Operation Of The Spool Gun PCB 7978034 .................................. 8-3

SECTION 9:PARTS LIST.................................................................................... 9-1

9.01 Equipment Identiﬁcation .......................................................................... 9-1

9.02 How To Use This Parts List ..................................................................... 9-1

9.03 External Replacement Parts ..................................................................... 9-2

9.04 Internal Replacement Parts (1) ................................................................ 9-4

9.05 Major Electrical and Mechanical Replacement Parts ............................... 9-6

9.06 Internal Replacement Parts (2) ................................................................ 9-7

9.07 Internal Replacement Parts-Spool Assembly .......................................... 9-8

9.08 Internal Replacement Parts-Wire Feeder ................................................. 9-9

9.09 Wire Feeder Replacement Parts ............................................................ 9-10

APPENDIX 1: OPTIONAL ACCESSORIES AND CONSUMABLES ...................................... A-1

APPENDIX 2: POWER SUPPLY CIRCUIT DIAGRAM .................................................... A-2

APPENDIX 3: FEEDROLL KITS ............................................................................ A-4

STATEMENT OF WARRANTY

WARRANTY SCHEDULE

FABRICATOR 251

Manual No. 0-4786B 1-1 SAFETY INSTRUCTIONS

1.01 Arc Welding Hazards

WARNING

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocks

or severe burns. The electrode and work circuit is

electrically live whenever the output is on. The input

power circuit and machine internal circuits are also live

when power is on. In semiautomatic or automatic wire

welding, the wire, wire reel, drive roll housing, and all

metal parts touching the welding wire are electrically

live. Incorrectly installed or improperly grounded

equipment is a hazard.

1. Do not touch live electrical parts.

2. Wear dry, hole-free insulating gloves and body protection.

3. Insulate yourself from work and ground using dry insulating

mats or covers.

4. Disconnect input power or stop engine before installing or

servicing this equipment. Lock input power disconnect switch

open, or remove line fuses so power cannot be turned on

accidentally.

5. Properly install and ground this equipment according to its

Owner’s Manual and national, state, and local codes.

6. Turn off all equipment when not in use. Disconnect power to

equipment if it will be left unattended or out of service.

7. Use fully insulated electrode holders. Never dip holder in water

to cool it or lay it down on the ground or the work surface. Do

not touch holders connected to two welding machines at the

same time or touch other people with the holder or electrode.

8. Do not use worn, damaged, undersized, or poorly spliced

cables.

9. Do not wrap cables around your body.

10. Ground the workpiece to a good electrical (earth) ground.

11. Do not touch electrode while in contact with the work (ground)

circuit.

12. Use only well-maintained equipment. Repair or replace

damaged parts at once.

13. In conﬁned spaces or damp locations, do not use a welder with

AC output unless it is equipped with a voltage reducer. Use

equipment with DC output.

14. Wear a safety harness to prevent falling if working above ﬂoor

level.

15. Keep all panels and covers securely in place.

WARNING

ARC RAYS can burn eyes and skin; NOISE can damage

hearing. Arc rays from the welding process produce

intense heat and strong ultraviolet rays that can

burn eyes and skin. Noise from some processes can

damage hearing.

1. Wear a welding helmet ﬁtted with a proper shade of ﬁlter (see

ANSI Z49.1 listed in Safety Standards) to protect your face and

eyes when welding or watching.

2. Wear approved safety glasses. Side shields recommended.

3. Use protective screens or barriers to protect others from ﬂash

and glare; warn others not to watch the arc.

SECTION 1:

SAFETY INSTRUCTIONS AND WARNINGS

!

WARNING

PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS KEEP

AWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSE THESE INSTRUCTIONS. READ OPERATING/INSTRUCTION MANUAL BEFORE

INSTALLING, OPERATING OR SERVICING THIS EQUIPMENT.

Welding products and welding processes can cause serious injury or death, or damage to other equipment or property, if the operator does

not strictly observe all safety rules and take precautionary actions.

Safe practices have developed from past experience in the use of welding and cutting. These practices must be learned through study and

training before using this equipment. Some of these practices apply to equipment

connected to power lines; other practices apply to engine driven equipment. Anyone not having extensive

training in welding and cutting practices should not attempt to weld.

Safe practices are outlined in the American National Standard Z49.1 entitled: SAFETY IN WELDING AND CUTTING. This publication and other

guides to what you should learn before operating this equipment are listed at the end of these safety precautions. HAVE ALL INSTALLATION,

OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE.

FABRICATOR 251

SAFETY INSTRUCTIONS 1-2 Manual No. 0-4786B

4. Wear protective clothing made from durable, flame-resistant

material (wool and leather) and foot protection.

5. Use approved ear plugs or ear muffs if noise level is high.

WARNING

FUMES AND GASES can be hazardous to your health.

Welding produces fumes and gases. Breathing these

fumes and gases can be hazardous to your health.

1. Keep your head out of the fumes. Do not breath the fumes.

2. If inside, ventilate the area and/or use exhaust at the arc to

remove welding fumes and gases.

3. If ventilation is poor, use an approved air-supplied respirator.

4. Read the Material Safety Data Sheets (MSDSs) and the

manufacturer’s instruction for metals, consumables, coatings,

and cleaners.

5. Work in a conﬁned space only if it is well ventilated, or while

wearing an air-supplied respirator. Shielding gases used for

welding can displace air causing injury or death. Be sure the

breathing air is safe.

6. Do not weld in locations near degreasing, cleaning, or spraying

operations. The heat and rays of the arc can react with vapors to

form highly toxic and irritating gases.

7. Do not weld on coated metals, such as galvanized, lead, or

cadmium plated steel, unless the coating is removed from the

weld area, the area is well ventilated, and if necessary, while

wearing an air-supplied respirator. The coatings and any metals

containing these elements can give off toxic fumes if welded.

WARNING

WELDING can cause ﬁre or explosion.

Sparks and spatter fly off from the welding arc.

The flying sparks and hot metal, weld spatter, hot

workpiece, and hot equipment can cause fires and

burns. Accidental contact of electrode or welding wire

to metal objects can cause sparks, overheating, or

ﬁre.

1. Protect yourself and others from ﬂying sparks and hot metal.

2. Do not weld where ﬂying sparks can strike ﬂammable material.

3. Remove all ﬂammables within 35 ft (10.7 m) of the welding arc.

If this is not possible, tightly cover them with approved covers.

4. Be alert that welding sparks and hot materials from welding can

easily go through small cracks and openings to adjacent areas.

5. Watch for ﬁre, and keep a ﬁre extinguisher nearby.

6. Be aware that welding on a ceiling, ﬂoor, bulkhead, or partition

can cause ﬁre on the hidden side.

7. Do not weld on closed containers such as tanks or drums.

8. Connect work cable to the work as close to the welding area

as practical to prevent welding current from traveling long,

possibly unknown paths and causing electric shock and fire

hazards.

9. Do not use welder to thaw frozen pipes.

10. Remove stick electrode from holder or cut off welding wire at

contact tip when not in use.

Eye protection ﬁlter shade selector for welding or cutting

(goggles or helmet), from AWS A6.2-73.

Welding or cutting

Operation

Electrode Size

Metal Thickness

or Welding Current

Filter

Shade

No.

Welding or cutting

Operation

Electrode Size

Metal Thickness

or Welding Current

Filter

Shade

No.

Torch soldering 2

Gas metal-arc

welding (MIG)

Torch brazing 3 or 4 Non-ferrous base metal All 11

Oxygen Cutting Ferrous base metal All 12

Light Under 1 in., 25 mm 3 or 4 Gas tungsten arc welding All 12

Medium 1 to 6 in., 25-150 mm 4 or 5 (TIG) All 12

Heavy Over 6 in., 150 mm 5 or 6 Atomic hydrogen welding All 12

Gas welding Carbon arc welding All 12

Light Under 1/8 in., 3 mm 4 or 5 Plasma arc welding

Medium 1/8 to 1/2 in., 3-12 mm 5 or 6 Carbon arc air gouging

Heavy Over 1/2 in., 12 mm 6 or 8 Light 12

Shielded metal-arc Under 5/32 in., 4 mm 10 Heavy 14

5/32 to 1/4 in., 12 Plasma arc cutting

Over 1/4 in., 6.4 mm 14 Light Under 300 Amp 9

Medium 300 to 400 Amp 12

Heavy Over 400 Amp 14

FABRICATOR 251

Manual No. 0-4786B 1-3 SAFETY INSTRUCTIONS

WARNING

FLYING SPARKS AND HOT METAL can cause injury.

Chipping and grinding cause flying metal. As welds

cool, they can throw off slag.

1. Wear approved face shield or safety goggles. Side shields

recommended.

2. Wear proper body protection to protect skin.

WARNING

CYLINDERS can explode if damaged.

Shielding gas cylinders contain gas under high

pressure. If damaged, a cylinder can explode. Since

gas cylinders are normally part of the welding process,

be sure to treat them carefully.

1. Protect compressed gas cylinders from excessive heat,

mechanical shocks, and arcs.

2. Install and secure cylinders in an upright position by chaining

them to a stationary support or equipment cylinder rack to

prevent falling or tipping.

3. Keep cylinders away from any welding or other electrical

circuits.

4. Never allow a welding electrode to touch any cylinder.

5. Use only correct shielding gas cylinders, regulators, hoses, and

ﬁttings designed for the speciﬁc application; maintain them and

associated parts in good condition.

6. Turn face away from valve outlet when opening cylinder valve.

7. Keep protective cap in place over valve except when cylinder is

in use or connected for use.

8. Read and follow instructions on compressed gas cylinders,

associated equipment, and CGA publication P-1 listed in Safety

Standards.

!

WARNING

Engines can be dangerous.

WARNING

ENGINE EXHAUST GASES can kill.

Engines produce harmful exhaust gases.

1. Use equipment outside in open, well-ventilated areas.

2. If used in a closed area, vent engine exhaust outside and away

from any building air intakes.

WARNING

ENGINE FUEL can cause ﬁre or explosion.

Engine fuel is highly ﬂammable.

1. Stop engine before checking or adding fuel.

2. Do not add fuel while smoking or if unit is near any sparks or

open ﬂames.

3. Allow engine to cool before fueling. If possible, check and add

fuel to cold engine before beginning job.

4. Do not overﬁll tank — allow room for fuel to expand.

5. Do not spill fuel. If fuel is spilled, clean up before starting

engine.

WARNING

MOVING PARTS can cause injury.

Moving parts, such as fans, rotors, and belts can cut ﬁngers and

hands and catch loose clothing.

1. Keep all doors, panels, covers, and guards closed and

securely in place.

2. Stop engine before installing or connecting unit.

3. Have only qualified people remove guards or covers for

maintenance and troubleshooting as necessary.

4. To prevent accidental starting during servicing, disconnect

negative (-) battery cable from battery.

5. Keep hands, hair, loose clothing, and tools away from

moving parts.

6. Reinstall panels or guards and close doors when servicing

is ﬁnished and before starting engine.

WARNING

SPARKS can cause BATTERY GASES TO EXPLODE;

BATTERY ACID can burn eyes and skin.

Batteries contain acid and generate explosive gases.

1. Always wear a face shield when working on a battery.

2. Stop engine before disconnecting or connecting battery cables.

3. Do not allow tools to cause sparks when working on a battery.

4. Do not use welder to charge batteries or jump start vehicles.

5. Observe correct polarity (+ and –) on batteries.

FABRICATOR 251

SAFETY INSTRUCTIONS 1-4 Manual No. 0-4786B

WARNING

STEAM AND PRESSURIZED HOT COOLANT can burn

face, eyes, and skin.

The coolant in the radiator can be very hot and under

pressure.

1. Do not remove radiator cap when engine is hot. Allow engine to

cool.

2. Wear gloves and put a rag over cap area when removing cap.

3. Allow pressure to escape before completely removing cap.

!

WARNING

This product, when used for welding or cutting,

produces fumes or gases which contain chemicals

know to the State of California to cause birth defects

and, in some cases, cancer. (California Health &

Safety code Sec. 25249.5 et seq.)

NOTE

Considerations About Welding And The Effects of Low

Frequency Electric and Magnetic Fields

The following is a quotation from the General Conclusions Section

of the U.S. Congress, Ofﬁce of Technology Assessment, Biological

Effects of Power Frequency Electric & Magnetic Fields - Background

Paper, OTA-BP-E-63 (Washington, DC: U.S. Government Printing

Ofﬁce, May 1989): “...there is now a very large volume of scientiﬁc

ﬁndings based on experiments at the cellular level and from studies

with animals and people which clearly establish that low frequency

magnetic ﬁelds and interact with, and produce changes in, biological

systems. While most of this work is of very high quality, the results

are complex. Current scientiﬁc understanding does not yet allow us

to interpret the evidence in a single coherent framework. Even more

frustrating, it does not yet allow us to draw definite conclusions

about questions of possible risk or to offer clear science-based ad-

vice on strategies to minimize or avoid potential risks.”

To reduce magnetic fields in the workplace, use the following

procedures.

1. Keep cables close together by twisting or taping them.

2. Arrange cables to one side and away from the operator.

3. Do not coil or drape cable around the body.

4. Keep welding power source and cables as far away from

body as practical.

ABOUT PACEMAKERS:

The above procedures are among those also normally

recommended for pacemaker wearers. Consult your

doctor for complete information.

1.02 Principal Safety Standards

Safety in Welding and Cutting, ANSI Standard Z49.1, from American

Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126.

Safety and Health Standards, OSHA 29 CFR 1910, from

Superintendent of Documents, U.S. Government Printing Office,

Washington, D.C. 20402.

Recommended Safe Practices for the Preparation for Welding

and Cutting of Containers That Have Held Hazardous Substances,

American Welding Society Standard AWS F4.1, from American

Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126.

National Electrical Code, NFPA Standard 70, from National Fire

Protection Association, Batterymarch Park, Quincy, MA 02269.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,

from Compressed Gas Association, 1235 Jefferson Davis Highway,

Suite 501, Arlington, VA 22202.

Code for Safety in Welding and Cutting, CSA Standard W117.2,

from Canadian Standards Association, Standards Sales, 178

Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3.

Safe Practices for Occupation and Educational Eye and Face

Protection, ANSI Standard Z87.1, from American National Standards

Institute, 1430 Broadway, New York, NY 10018.

Cutting and Welding Processes, NFPA Standard 51B, from National

Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

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FABRICATOR 251

SAFETY INSTRUCTIONS 1-8 Manual No. 0-4786B

AVERTISSEMENT

LE CARBURANT PEUR CAUSER UN INCENDIE OU

UNE EXPLOSION.

Le carburant est hautement inﬂammable.

1. A r r ê t e z l e mo t e u r a v a n t d e v é r i f i e r l e n i v e a u e

carburant ou de faire le plein.

2. Ne faites pas le plein en fumant ou proche d’une source d’étin-

celles ou d’une ﬂamme nue.

3. Si c’est possible, laissez le moteur refroidir avant de faire le

plein de carburant ou d’en vériﬁer le niveau au début du soud-

age.

4. Ne faites pas le plein de carburant à ras bord: prévoyez de l’

espace pour son expansion.

5. Faites attention de ne pas renverser de carburant. Nettoyez tout

carburant renversé avant de faire démarrer le moteur.

AVERTISSEMENTAVERTISSEMENT

DES PIECES EN MOUVEMENT PEUVENT CAUSER DES

BLESSURES.

Des pièces en mouvement, tels des ventilateurs, des

rotors et des courroies peuvent couper doigts et

mains, ou accrocher des vêtements amples.

1. Assurez-vous que les portes, les panneaux, les capots et les

protecteurs soient bien fermés.

2. Avant d’installer ou de connecter un système, arrêtez le moteur.

3. Seules des personnes qualifiées doivent démonter des pro-

tecteurs ou des capots pour faire l’entretien ou le dépannage

nécessaire.

4. Pour empêcher un démarrage accidentel pendant l’entretien,

débranchez le câble d’accumulateur à la borne négative.

5. N’approchez pas les mains ou les cheveux de pièces en mouve-

ment; elles peuvent aussi accrocher des vêtements amples et

des outils.

6. Réinstallez les capots ou les protecteurs et fermez les portes

après des travaux d’entretien et avant de faire démarrer le mo-

teur.

AVERTISSEMENT

DES ETINCELLES PEUVENT FAIRE EXPLOSER UN

ACCUMULATEUR; L’ELECTROLYTE D’UN ACCUMU-

LATEUR PEUT BRULER LA PEAU ET LES YEUX.

Les accumulateurs contiennent de l’électrolyte acide et

dégagent des vapeurs explosives.

1. Portez toujours un écran facial en travaillant sur un accumu-

lateur.

2. Arrêtez le moteur avant de connecter ou de déconnecter des

câbles d’accumulateur.

3. N’utilisez que des outils anti-étincelles pour travailler sur un ac-

cumulateur.

4. N’utilisez pas une source de courant de soudage pour charger

un accumulateur ou survolter momentanément un véhicule.

5. Utilisez la polarité correcte (+ et –) de l’accumulateur.

AVERTISSEMENT

LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT

BRULANT SOUS PRESSION PEUVENT BRULER LA

PEAU ET LES YEUX.

Le liquide de refroidissement d’un radiateur peut être

brûlant et sous pression.

1. N’ôtez pas le bouchon de radiateur tant que le moteur n’est pas

refroidi.

2. Mettez des gants et posez un torchon sur le bouchon pour l’ôter.

3. Laissez la pression s’échapper avant d’ôter complètement le

bouchon.

1.05 Principales Normes De Securite

Safety in Welding and Cutting, norme ANSI Z49.1, American Weld-

ing Society, 550 N.W. LeJeune Rd., Miami, FL 33128.

Safety and Health Standards, OSHA 29 CFR 1910, Superintendent

of Documents, U.S. Government Printing Ofﬁce, Washington, D.C.

20402.

Recommended Safe Practices for the Preparation for Welding and

Cutting of Containers That Have Held Hazardous Substances, norme

AWS F4.1, American Welding Society, 550 N.W. LeJeune Rd., Miami,

FL 33128.

National Electrical Code, norme 70 NFPA, National Fire Protection

Association, Batterymarch Park, Quincy, MA 02269.

Safe Handling of Compressed Gases in Cylinders, document P-1,

Compressed Gas Association, 1235 Jefferson Davis Highway, Suite

501, Arlington, VA 22202.

Code for Safety in Welding and Cutting, norme CSA W117.2 Asso-

ciation canadienne de normalisation, Standards Sales, 276 Rexdale

Boulevard, Rexdale, Ontario, Canada M9W 1R3.

Safe Practices for Occupation and Educational Eye and Face Protec-

tion, norme ANSI Z87.1, American National Standards Institute,

1430 Broadway, New York, NY 10018.

Cutting and Welding Processes, norme 51B NFPA, National Fire Pro-

tection Association, Batterymarch Park, Quincy, MA 02269.

FABRICATOR 251

Manual No. 0-4786B 2-1 INTRODUCTION

SECTION 2:

INTRODUCTION

2.01 How To Use This Manual

This Service Manual applies to only the speciﬁcation or

part numbers listed on page i.

To ensure safe operation, read the entire manual,

including the chapter on safety instructions and

warnings.

Throughout this manual, the words WARNING,

CAUTION, and NOTE may appear. Pay particular

attention to the information provided under these

headings. These special annotations are easily

recognized asfollows:

!

WARNING

A WARNING gives information regarding

possible personal injury.

CAUTION

A CAUTION refers to possible equipment

damage.

NOTE

A NOTE offers helpful information

concerning certain operating procedures.

Additional copies of this manual may be purchased

by contacting Thermadyne at the address and phone

number in your area listed in the inside back cover of

this manual. Include the Service Manual number and

equipment identiﬁcation numbers.

Electronic copies of this manual can also be downloaded

at no charge in Acrobat PDF format by going to the

Thermal Arc web site listed below and clicking on the

Literature link:

http://www.thermalarc.com

2.02 Equipment Identiﬁcation

The unit’s identiﬁcation number (speciﬁcation or part

number), model, and serial number usually appear on

a nameplate attached to the rear panel. In some cases,

the nameplate may be attached to the control panel.

Equipment which does not have a name plate such

as gun and cable assemblies is identiﬁed only by the

specification or part number printed on the shipping

container. Record these numbers on the bottom of

page i for future reference.

FABRICATOR 251

INTRODUCTION 2-2 Manual No. 0-4786B

2.03 Symbol Chart

Note that only some of these symbols will appear on your model.

Gas Tungsten Arc

Welding (GTAW)

Air Carbon Arc

Cutting (CAC-A)

Constant Current

Constant Voltage

Or Constant Potential

High Temperature

Fault Indication

Arc Force

Touch Start (GTAW)

Variable Inductance

Voltage Input

Single Phase

Three Phase

Three Phase Static

Frequency Converter-

Transformer-Rectifier

Dangerous Voltage

Off

On

Panel/Local

Shielded Metal

Arc Welding (SMAW)

Gas Metal Arc

Welding (GMAW)

Increase/Decrease

Circuit Breaker

AC Auxiliary Power

Remote

Duty Cycle

Percentage

Amperage

Voltage

Hertz (cycles/sec)

Frequency

Negative

Positive

Direct Current (DC)

Protective Earth

(Ground)

Line

Line Connection

Auxiliary Power

Receptacle Rating-

Auxiliary Power

Art # A-04130

115V 15A

t

t1

t2

%

X

IPM

MPM

t

V

Fuse

Wire Feed Function

Wire Feed Towards

Workpiece With

Output Voltage Off.

Preflow Time

Postflow Time

Spot Time

Spot Weld Mode

Continuous Weld

Mode

Press to initiate wirefeed and

welding, release to stop.

Purging Of Gas

Inches Per Minute

Meters Per Minute

Welding Gun

Burnback Time

Press and hold for preflow, release

to start arc. Press to stop arc, and

hold for preflow.

4 Step Trigger

Operation

2 Step Trigger

Operation

FABRICATOR 251

Manual No. 0-4786B 2-3 INTRODUCTION

2.04 General Information

The Fabricator 251 is a semiautomatic Gas Metal Arc

Welder (GMAW-commonly MIG) with an integrated wire

feed unit. The Power Supply is designed to meet the

broad operating needs of the metal fabrication industry

where production efﬁciency is vital. The Fabricator 251

is designed and manufactured to meet the requirements

of CSA and IEC 60974-1 standards.

The Fabricator 251 gives excellent performance on

mild steel, stainless steel, aluminum, silicon bronze

and some hard facing wires with Argon based shielding

gases. The Power Supply also gives excellent results on

mild steel using Carbon Dioxide shielding gas.

The Fabricator 251 is supplied as a complete package

ready to weld (apart from gas cylinder and electrode

wire). The following instructions detail how to correctly

set up the welder and give guidelines on gaining the

best production efficiency from the Power Supply.

Please read these instructions thoroughly before using

your Fabricator welder.

2.05 Safety

The following basic safety rules should always be fol-

lowed:

• Ensure the machine is correctly installed, if neces-

sary, by a qualiﬁed electrician.

• Ensure the Power Supply is grounded correctly

(electrically) in accordance with local regulations.

• Excessive heat in the welding cables may cause

ﬁre. Never weld with poor electrical connections,

damaged welding cables or exceed the welding

cable current rating as this will produce excessive

heat and may cause a ﬁre.

• Always wear the correct protective clothing for

protection from sparks, molten particles and arc

rays.

• When welding in conﬁned spaces, always ensure

adequate ventilation and constant observation of

the operator.

• Keep combustible materials away from the weld-

ing area. Have a suitable ﬁre extinguisher handy.

• Never watch the welding arc with naked eyes. Al-

ways use and wear a welding mask ﬁtted with the

correct ﬁlter lens.

• Do not stand on damp ground when welding.

For more complete safety advice please read section 1.

2.06 Protective Filter Lenses

Protective filter lenses are provided to reduce the

intensity of radiation entering the eye thus ﬁltering out

harmful infrared, ultraviolet radiation and a percentage

of the visible light. Such ﬁlter lenses are incorporated

within face shields. To prevent damage to the filter

lenses from molten or hard particles an additional hard

clear glass or special plastic external cover lens should

be used. This cover lens should always be kept in place

and replaced before the damage impairs your vision

while welding.

Approximate range of

welding current

Filter lens

required for

MIG

Up to 150 Shade 10

150-250 Shade 11

250-300

Shade 12

300-350

Shade 13

Over 350

Shade 14

Table 2-1: Filter Lens Size Versus Welding Current

It is recommended to use a welding helmet, conforming

to the local relevant Standards when electric arc

welding. Use a welding helmet in serviceable condition

with the correct ﬁlter lens. Refer to Table 2-1 above and

AWS table in Section 1.

2.07 User Responsibility

This equipment will perform as per the information

contained herein when installed, operated, maintained

and repaired in accordance with the instructions

provided. This equipment must be checked periodically.

Defective equipment (including welding leads) should

not be used. Parts that are broken, missing, plainly

worn, distorted or contaminated, should be replaced

immediately. Should such repairs or replacements

become necessary, it is recommended that such repairs

be carried out by appropriately qualified persons

approved by Thermal Arc. Advice in this regard can be

obtained by contacting Thermal Arc.

This equipment or any of its parts should not be

altered from standard specification without prior

written approval of Thermal Arc. The purchaser of

this equipment shall have the sole responsibility for

any malfunction which results from improper use or

unauthorized modiﬁcation from standard speciﬁcation,

FABRICATOR 251

INTRODUCTION 2-4 Manual No. 0-4786B

faulty maintenance, damage or improper repair by anyone other than appropriately qualiﬁed persons approved by

Thermal Arc.

2.08 Duty Cycle

The rated duty cycle of a welding Power Supply is the operating time it may be used at its rated output current

without exceeding the temperature limits of the insulation of the component parts. To explain the ten minute duty

cycle period the following example is used. Suppose a welding Power Supply is designed to operate at 60% duty

cycle, 250 amperes at 26.5 volts. This means that it has been designed and built to provide the rated amperage

(250A) at the rated load voltage (26.5V), for 6.0 minutes out of every 10 minute period (60% of 10 minutes is 6.0

minutes). During the other 4.0 minutes of the 10 minute period the Power Supply must idle and be allowed to cool.

The thermal cutout will operate if the duty cycle is exceeded.

2.09 Speciﬁcations for Fabricator 251

MIG Gun Speciﬁcations

Gun Catalog Number 43340

Gun Type TWECO Weldskill 300 Amp

Gun Cable Length 15 ft (4.5m)

Table 2-2: MIG Gun Speciﬁcations

Wire Drive Speciﬁcations Fabricator 251

Control Circuit Supply 30VA @ 32VAC

Wire Drive Motor Supply 180VA @ 14 to 46VAC

Wire Speed Range

80 to 800 ipm

(2 to 20 m/min)

Wire Diameter

.023"

(0.6mm)

.030"

(0.8mm)

.035"

(0.9mm)

.045"

(1.2mm)

1/16"

(1.6mm)

Mild Steel: Y Y Y Y

Stainless Steel: Y Y Y Y

Aluminum: Y Y Y Y

Flux Cored: Y Y Y Y

Wire Spool Size Capacity 44 lb, 33 lb, 10 lb, 8" and 12" wire spool sizes.

Table 2-3: Wire Drive Speciﬁcations

FABRICATOR 251

Manual No. 0-4786B 2-5 INTRODUCTION

Fabricator 251

Package System Part Number 100048D-002

Power Source Part Number 707237

Power Source Weight 227lb (103kg)

Power Source Dimensions HxWxD

(including wheels and cylinder carrier)

32” x 27-3/16” x 36-3/4”

(813 x 691 x 933mm)

Nominal Input Voltage 208V 230V

Number of Phases 1Ø

Frequency 60 Hz

Flexible Supply Cable Size

Supply Plug

10ft (3m) 10AWG

NEMA 6-50P

Rated Input Current @ 100% Duty Cycle * 36A * 32.6A

Rated kVA @ 100% Duty Cycle 7.5 kVA 7.5 kVA

Maximum Input Current @ 250A Output 68A 62A

Generator Requirements 20 kVA 20 kVA

Supply VA @ Maximum Output 15 kVA 15 kVA

Recommended Primary Circuit Size 50A 50A

Recommended Minimum Primary Fuse Size ** 70A ** 70A

Open Circuit Voltage Range 15.6 – 45.9V DC 15.6 – 45.9V DC

Welding Arc Voltage Range 14.5 – 31.7V DC 14.5 – 31.7V DC

Output Current Range 20 – 300A DC 20 – 300A DC

Rated Output Duty Cycle @ 104ºF 250A/26.5V @ 60% 250A/26.5V @ 60%

Maximum Duty Cycle @ 104ºF 300A/31.7V @ 40% 300A/31.7V @ 40%

100% Duty Cycle Output Rating @ 104ºF 195A DC at 24V 195A DC at 24V

Duty Cycle Period 10 minutes

Number of Output Voltage Values 24

Electrode Wire Type and Diameter

Mild / Stainless Steel .023” (0.6mm) – .045” (1.2mm)

Aluminum .030” (0.8mm) – 1/16” (1.6mm)

Flux Cored .030” (0.8mm) – 1/16” (1.6mm)

Wire Feed Speed Range 80 – 800 ipm (2 – 20 m/min )

Wire Spool Size Diameter 8” / 12” (200mm / 300mm)

Burn-Back Timer Range 0 – 0.6 seconds

Burn-Back Time Factory Set to 0.16 seconds

Spot Timer Range 0.5 – 9 seconds

Dwell Timer Range 1 – 12 seconds

Stitch Weld Time Weld (Stitch) Time 0.5 – 9 seconds

Dwell (non-weld) Time 1 – 12 seconds

Thermal Protection Self-resetting thermostat ﬁtted to rectiﬁer and

transformer

Operating Temperature Range 32° to 104°F (0° to 40°C)

* The Rated Input Current should be used for the determination of cable size & supply

requirements.

** Motor start fuses or thermal circuit breakers are recommended for this application.

Check local requirements for your situation in this regard.

Table 2-4: Machine Speciﬁcations

FABRICATOR 251

INTRODUCTION 2-6 Manual No. 0-4786B

2.10 Included Items for Fabricator 251

Fabricator 251 Package System Contents

Factory Fitted Wheeling Kit Y

Factory Fitted Dual Cylinder Rack Y

Factory Fitted Primary Power Cable 8AWG, 10ft (3m) with Plug

NEMA 6-50P

Y

Work Lead 10ft (3m) Y

Cable Stowage Hooks Y

Regulator/Flow Meter – Argon Mix Gases Y

Tweco Weldskill MIG Gun 300 Amp, 15ft (4.5m) Y

Fitted Feed Roll for .035” - .045” (0.9 – 1.2mm) solid wire Y

Accessories Box Y

Table 2-8: Power Supply Contents

2.11 Optional Accessories

Refer to the Appendix section of this manual for the list of available options and accessories.

FABRICATOR 251

Manual No. 0-4786B 3-1 INSTALLATION

SECTION 3:

INSTALLATION

3.01 Environment

The Fabricator 251 is NOT designed for use in

environments with increased hazard of electric shock.

Examples of environments with increased hazard of

electric shock are:

In locations in which freedom of movement is

restricted, so that the operator is forced to perform the

work in a cramped (kneeling, sitting or lying) position

with physical contact with conductive parts;

In locations which are fully or partially limited by

conductive elements, and in which there is a high risk

of unavoidable or accidental contact by the operator, or

In wet or damp hot locations where humidity or

perspiration considerably reduces the skin resistance

of the human body and the insulation properties of

accessories.

Environments with increased hazard of electric shock

do not include places where electrically conductive

parts in the near vicinity of the operator, which can

cause increased hazard, have been insulated.

3.02 Location

Be sure to locate the Power Supply according to the

following guidelines:

In areas, free from moisture and dust.

In areas, free from oil, steam and corrosive gases.

In areas, not subjected to abnormal vibration or shock.

In areas, not exposed to direct sunlight or rain.

Place at a distance of 1 foot (300 mm) or more from

walls or similar that could restrict natural air ﬂow for

cooling.

The minimum ground clearance for these products is

5.5" (140mm).

3.03 Ventilation

Since the inhalation of welding fumes can be harmful,

ensure that the welding area is effectively ventilated.

FABRICATOR 251

INSTALLATION 3-2 Manual No. 0-4786B

3.04 Primary Power Requirements

The primary supply voltage should be within ± 10% of the rated primary supply voltage. Too low of a supply

voltage may cause poor welding performance or wirefeeder malfunction. Too high of a supply voltage will cause

components to overheat and possibly fail.

Install a power outlet for each Power Supply and ﬁt fuses as per the machine speciﬁcations.

!

WARNING

Thermal Arc advises that your Fabricator 251 be electrically connected by a qualiﬁed electrical trades-

person.

The Fabricator 251 Power Supply is factory connected for the following input power supply voltage:

Input Power Supply

Lead Size

Lead Current

Rating

Lead

Length

Machine Voltage

Setting Duty Cycle

8 AWG 40 Amps 10ft (3m) 230V 250A @ 60%

Table 3-1: Factory Fitted Input Power Supply Leads Fitted to the Fabricator 251

3.05 Alternative Primary Input

!

WARNING

The Fabricator 251 input power supply lead should be replaced with leads as speciﬁed in Table 3-2 when

the Fabricators input power supply voltage is changed.

The Power Supply is suitable for use on the following input power supply voltages:

Input Power Supply

Voltage Setting

Primary Input

Supply Lead Size

Input Power

Outlet Size Fuse Size Duty Cycle

208V 8AWG (8.0mm2) 50 Amps *70Amp 250A @ 60%

230V 8AWG (8.0mm2) 50 Amps *70Amp 250A @ 60%

Table 3-2: Primary Input Supply Lead Sizes for Alternative Mains Supply Voltages

*Motor start fuses or thermal circuit breakers are recommended for this application. National Electrical Code

Standards permit the rating of the fuse or thermal circuit breaker protecting the circuit conductors to be double the

standard rating for any circuit used exclusively for an electric arc welder. Check local requirements for your situation

in this regard.

FABRICATOR 251

Manual No. 0-4786B 3-3 INSTALLATION

Changing the Voltage Selection

1. Disconnect the power supply from the input power source.

2. Refer to Figure 3-1. The power supply comes wired for 230V. Locate the two blue input power wires where

they are secured to the input voltage selection block. Loosen the set screw for both voltage locations.

3. Remove the blue wires from the current location and Insert them into the new voltage location. Secure by tight-

ening the set screw onto the uninsulated portion of the wires. Secure the other voltage set screw as well.

230V connection

208V connection

Art # A-07332

Figure 3-1: Voltage Selections for Fabricator 251 (Wired for 230V)

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ESAB 251 FABRICATOR® Mig Welding Machine User manual

ESAB 251 FABRICATOR® Mig Welding Machine User manual

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